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Tag: packaging automation

Customer Experience Matters in Packaging

Posted on by David Priestman

Ecommerce, fulfilment, automation and sustainability trends have pushed the packaging machinery sector into the limelight and forefront of handling and logistics. David Priestman spoke to Coesia’s Fabrizio Sasdelli to learn about the wide range of products and solutions now available.

Coesia, head-quartered in Bologna, are perhaps a well-kept secret in the ecommerce and logistics sector, being a much bigger company than perhaps people realise, with 8000 staff, 20 companies, 87 manufacturing plants and a turnover of €2 billion. What readers will be interested in is what the company does in terms of wrapping, palletizing, robotics, carton boxing and end-of-line, fulfilment products. I asked Fabrizio Sasdelli, E-Commerce Business Line Director, about the different brands and divisions.

Fabrizio Sasdelli, Coesia

Fabrizio Sasdelli: As you mentioned, Coesia includes more than 20 companies, grouped into three main divisions. The Regulated Markets Solutions (RMS) division covers areas like packaging systems. The Consumer Market Solutions (CMS) division focuses on products typically found in a supermarket, such as powders, liquids and solids. The Industrial Market Solutions (IMS) division handles automation and includes companies brought together for strategic synergies.

Our aim is to combine expertise across industrial automation, software and process engineering. We have a strong engineering core and a central division that supports all group companies in accelerating solution development, including tools like digital twins for project evaluation. What sets Coesia apart is our ability to integrate specialised know-how across the group. The collaboration between companies acts as a shared platform, enabling the creation of customised and scalable solutions.

We provide packaging systems within fulfilment workflows, while also developing finished products. Our technologies support right-size packaging and efficient shipment composition, which help reduce environmental impact. The result is a smoother process, faster response times and high operational reliability. With our global footprint, we ensure continuous support to customers around the world.

Logistics Business (LB): What are the key product developments?

Sasdelli: We have two big groups: packaging-on-demand, and automation. When required we can also integrate the two. In terms of solutions, this includes carton packaging, box resizing, digital printing on demand, and printing in the box. Then we have all the robotics: palletising, robot picking, and AMRs, plus conveying systems, where we are very strong, and vertical sorters. Right-size boxing means that we do not have standard boxes, but we can customise size, based on random products, creating the right parcel.

LB: I want to go in detail about the Emmeci business and the fit-to-size carton machines.

Sasdelli: Yes, Emmeci offers a range of fit-to-size machines. For example, we can produce custom-sized American boxes that adapt to different product dimensions, from small items up to larger parcels. Each box can be individually adjusted, using data from the warehouse management system (WMS). The system supports both automatic and manual box definition, and the packaging process begins as soon as the product arrives.

The E-BFS is ideal for single or multi-item orders. It creates right-sized clamshell boxes, integrating box making, filling, sealing and labelling. It also supports personalisation, including printed invoices or marketing inserts, based on customer data. Return handling can be built into the design as well. The E-SWL produces right-sized paper bags in various formats. It includes an automated carton erector for minimal manual intervention and precise adjustment of box height. We also offer the Autobagger, a compact modular machine for shipping bags. It fits easily into existing operations and can run up to 1,200 boxes per minute, or less, depending on requirements.

We also provide a vertical bagger and a wide portfolio to cover diverse packaging needs. Few competitors can match this breadth. Our systems are highly customisable and scalable, with options for both automated and semi-automated setups. We tailor our solutions to match different warehouse configurations and customer workflows.

LB: You mentioned a few other products which we can talk about, such as Flexlink’s conveyors, palletizers, robotics, sorters, AMRs as well?

Sasdelli: Flexlink manages all the automation, which affects everything. It is very strong and is used to working with other group companies, connecting different machines and providing direction.

LB: Palletising, particularly robotic palletising, is very much in vogue now, isn’t it? A lot of companies are partnering and automating that part of the outbound process. What palletizer machines do you have? What is it that Coesia manufactures? Everything including the robotic arm? Or are you buying that from a supplier?

Sasdelli: We recognise the growing demand for robotic palletising. At Coesia, our company FlexLink offers smart, space-saving and easy-to-integrate solutions for both inbound and outbound operations. One of our key offerings is the RC12 collaborative palletiser, now in its third generation. It is ideal for end-of-line processes where space is limited, as it uses more than 50 percent less floor space compared to standard industrial robots. It is also very user-friendly. Operators can create pallet patterns without needing any programming skills, thanks to the intuitive software.

The RC12 can handle up to 14 boxes per minute using a double gripper. It meets international safety standards for collaborative robots and works safely without cages or barriers. For larger and faster operations, we also offer the RI20 industrial palletiser. This solution is designed for continuous use and delivers high throughput with great precision.

We also focus on software and system intelligence. Our in-house algorithms manage different box sizes efficiently. For example, we can use scanners to detect incoming boxes, buffer them, and then optimise pallet building. The system ensures fast operation, stable pallet formation and maximum volume use, even when box sizes vary by just a few millimetres. We are flexible when it comes to robotic arms. The RC12 integrates an Omron arm, but we can work with whichever brand the customer prefers. What matters most is providing a reliable and efficient palletising system that fits the customer’s needs.

LB: In terms of right size packaging, not wasting or shipping air has been a trend in recent years. We see this with companies that we report on in the sector like Spark and CMC. Bottom line, what kind of savings have you been able to make customers in recent years with e-commerce in terms of the right size packaging and reducing the amount of packaging waste, space and void in the final package?

Sasdelli: It depends on the application. There are cases where we used to have a standard size, where we have seen a lot of cases where they put inside 1:10 and 1:00. Just one book and 99% of the volume is fully empty! Like this we can save packaging by using the right size that can help in this way. When you are used to having a standard box and you have volumes that can change a lot, I think that you can really save a huge amount.

LB: Sustainability and automation. What would you say would be another big issue that you’re focusing on with customers?

Sasdelli: Sustainability is a major focus for us. We’re investing significant resources into programmes that directly influence the design and efficiency of our machines. We help customers reduce energy and material consumption, and our solutions often include tailored automation that meets specific sustainability goals.

Another key strength is our engineering capability. The Coesia group has built deep synergies across its companies, which allows us to offer flexible and highly customised solutions. We also have a strong environmental certification department that supports customers with compliance and optimisation. Ultimately, our aim is to design systems that reduce waste, minimise packaging volume and lower the overall environmental impact.

LB: I was talking to Jo Bradley at Spark Technologies about a year ago and I asked what’s your biggest competition? Expecting her to name other companies, she said actually, it’s the unavailability of manual labour. Lots of customers are buying automated packaging machines because they simply cannot get the staff to do the manual process. So most of their wins are actually replacing manual operations, rather than directly going head-to-head with another automation supplier. Do you find the same in most of your markets now?

Sasdelli: Yes, we see that trend in many markets, especially in Germany. Finding skilled labour is becoming increasingly difficult, particularly during peak periods or when companies scale quickly. Automation becomes the only practical solution to maintain efficiency and reliability. It’s not just about reducing manual effort, but also about ensuring consistent performance where labour simply isn’t available.

LB: Are there any typical packaging products that you don’t manufacture yourselves? I’m thinking of stretch wrap or shrink-wrapping machines, do you do you provide those as well or do you buy those in?

Sasdelli: In most cases, we can provide what the customer needs. When specific packaging products like stretch or shrink-wrapping machines are not part of our standard portfolio, we collaborate with trusted suppliers. We are always open to integration partnerships to deliver a complete solution. FlexLink, part of the Coesia group, has over 40 years of experience as a systems integrator. They are experts in designing complex automation setups and often work alongside both internal companies and external partners, including market companions. This flexibility allows us to choose the best technology for each project and ensure it fits the customer’s requirements perfectly.

LB: What would be the largest scale e-commerce projects that you’ve worked on recently, in terms of the implementation, number of machines or facilities?

Sasdelli: In our largest e-commerce projects, we typically combine two or three core machines with a full automation setup. End-of-line palletizing is almost always included. One of our key strengths is delivering both the packaging systems and the automation that connects everything into a complete solution. Depending on the project, we might integrate labelling units, palletizers, and robotic or manual workstations. For larger operations, we have deployed up to ten robots. We also create a digital twin of the entire system, allowing us to fine-tune performance together with the customer and ensure the solution is exactly right.

LB: You’re using a lot of simulation while you’re consulting for projects?

Sasdelli: Yes, we have dedicated staff who support simulation activities and can assist in creating complete models for each project. It is not just about visualising the flow, dimensions or footprint, but also about accurately sizing the system’s capacity. This includes determining how many workstations are needed to handle different scenarios. We evaluate various possibilities, verify the most effective solution and design the integration accordingly.

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Packaging Innovation Day is Borderless Success

Posted on by Keith McKinley

With over 150 international attendees representing 92 leading companies in the world of eCommerce and logistics, the 2025 edition of CMC’s Innovation Day on Wednesday concluded with outstanding success. Held at the CMC Packaging Automation headquarters in Città di Castello, the event reaffirmed the company’s central role as a global benchmark in packaging automation.

This year’s theme, LIMITLESS, served as the guiding thread for a day filled with insights, visionary thinking, and innovations that are reshaping the future of right-sized packaging. The morning conference featured presentations from international customers, system integrators, and industry leaders who shared real-world case studies and emerging market trends. Logistics Business will bring you the full story in our next issue.

Among the speakers were DHL – who presented its project with Adidas; Avantor and Element Logic – who highlighted their joint project in Germany and the crucial role of CMC Genesys integration with AutoStore; and eMAG – the largest eCommerce player in Eastern Europe, who presented its packaging automation project developed in partnership with CMC. Exotec offered insight on the importance of right-sized packaging in complementing the new Skypod system.

In the afternoon, guests visited CMC’s production facility for exclusive demonstrations of the full range of on-demand packaging solutions and two of 2025’s key technological innovations:

• CMC Super Vertical: an ultra-compact machine capable of producing right-sized boxes and mailers, specifically designed for small to mid-sized distribution centers. It is ideal for retrofit projects and for maximizing space without compromising productivity.

• New CMC Genesys Concept and Genesys PRIMA: a scalable and modular machine, able to operate either as a stand-alone box-first solution or integrated within warehouse workflows. With the integration of CMC’s patented Vary-Tote technology, the system can handle irregularly shaped products within advanced pick-to-pack processes.

The event also saw a strong presence of system integrators from across the globe, eager to explore the flexibility and scalability of CMC’s solutions for end-to-end project implementations.
Underscoring the event’s success and rising international demand, CMC announced that, for the first time, Innovation Day will also be held at its Tech Centre in Atlanta, Georgia on July 16th. Already functioning as a training hub and testing lab for clients and technology partners, the U.S. site will host the second edition of CID25 to offer an immersive experience to the North American market.

“Integration is no longer optional — it’s essential. At CMC, we believe that innovation must start with listening. Since 1980, we’ve helped companies improve their fulfillment processes and achieve their sustainability goals through high-speed, high-performance technology. In recent years, market demand has shifted: businesses now need scalable solutions that can be deployed in existing, space-constrained environments. This is what has driven our R&D efforts. The result is a new generation of ultra-compact, intelligent systems that can handle a wide variety of items without compromising on package integrity or throughput. With CID25, we wanted to demonstrate that when innovation is driven by vision and passion, there are no limits,” said Francesco Ponti, CMC Executive Chairman and CEO.

Tania Torcolacci, Head of Global Marketing and Strategic Partnerships at CMC, added: “The excitement we received during the event encouraged us to extend Innovation Day to the U.S., where we aim to replicate the energy, dialogue, and value generated here in Italy.”

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Right to Repair needs Right-size Approach

Posted on by David Priestman

‘Right to Repair’ legislation is having an impact on consumer goods manufacturers and spare parts stockists in at least four States in the US, and those waves are being felt too, by OEMs in Europe and the UK, writes Jo Bradley, Business Development Manager at Sparck Technologies.

Perhaps not before time, the backlash against the ‘disposable society’ is in full swing. This is great news for the environment – not so great for the many companies who will face some serious packaging problems.

For many decades, ‘spares and repairs’ has been an industrial orphan – across a wide range of consumer goods, and indeed commercial equipment, it has been cheaper to send a broken item to landfill and buy a replacement rather than to have it repaired. In many cases the design and manufacture renders even simple repairs not just economically prohibitive but physically impossible. But under pressure from both consumers and regulators, this is changing.

In the US, at least four States have brought in versions of ‘Right to Repair’ legislation. In the European Union, the European Parliament early last year adopted a Directive extending existing laws to require manufacturers, initially of common household goods from washing machines to smartphones, either to repair damaged items, or to make spare parts, tools and instructions available to consumers and third party repair shops ‘at reasonable prices’. In the UK, major retailers including Currys (electricals/electronics) and the department store John Lewis are making a big thing of their repair services. This is in addition to the usual service of ‘consumable’ spares such as replacement filters.

But this will mean a big increase in the number of packages moving through different lanes. OEMs, or their parts stockists, will have to supply individual items, or ‘kits’ of parts and tools, both to repair specialists and direct to consumers, while the repair shops have to pack and despatch renovated products back to their owners. In the industrial and commercial sectors, suppliers to MRO (Maintenance, Repairs, Operations) activities – not just spare parts but also tools and consumables such as drill bits – already face similar challenges.

The range of items involved is intimidating. A washing machine repair might involve a new drum, or just a new microswitch. Under some of the new laws products have to be supported for many years so the number of different parts is vast. In automotive, where of course ‘spares and repairs’ never went away, we know a US client with 1.3 million part numbers in their catalogue – and that is just to support their niche market of imported German cars! Clearly, packing everything into the same narrow range of ‘standard’ boxes or cartons is a non-starter.

And many or perhaps, given the advance of electronics, most spare parts are small both in size and in value. Small items generally require proportionately more packaging material – coupled with labour costs it is no surprise that packing can cost more than the value of the goods. In many cases, supporting repairs is inherently uneconomic; the more so if spares are required to be supplied ‘at reasonable prices’. And shipping costs too can be disproportionate for small boxes, especially if the box is larger than it needs to be.

So OEMs, stockists and repair shops need to bear down heavily on the costs of pick, pack and dispatch. Smart automation of these operations will be critical, and luckily, ‘right-sizing’ boxes for dispatch can now be a fast, automatic process that can produce over 1000 boxes an hour.

Sparck Technologies’ automated boxing systems not only replace most of the labour required in manual operations – one or two operators on a machine can achieve the same throughput as up to 20 manual stations – but for individual items or ‘kits of parts’ can create boxes that are ‘fitted to size’ for each order. The item or assemblage is 3D scanned, the optimum size and shape of box calculated, board is cut, creased, erected, sealed, weighed and labelled. If required, the machine can keep producing ‘standard’ (not necessarily the carton industry’s standard) boxes until a ‘special’ is needed. There is also the option to split operations so that a ‘tray’ is produced into which items can be picked, and which is then united with its ‘lid’ elsewhere. Sparck’s CVP machines can handle weights of up to 30kg, and at the other end of the scale create boxes as shallow as 28mm.

The CVP Impack range can pack at up to 500 orders an hour, or one every seven seconds, while the CVP Everest range achieves an impressive 1,100 per hour – one box every three seconds, and unlike with manual packing, this performance doesn’t tail off towards the end of the shift.

Besides these labour savings and productivity gains, there are many other benefits. Savings in the use of board of typically 30% are commonplace, while void fill – typically non-recyclable – can be greatly reduced or even eliminated. Right-size boxes economise on postage or courier rates, particularly when these are based on ‘volumetric weight’, and make more efficient use of transport. Creating boxes at the point of use means that there is no need to store large numbers of pre-forms or erected boxes. With one machine you’ve got more than 40 million box sizes at your disposal. And packaging that fits the items snugly reduces the risk of transit damage. This all saves money, pleases the customer and is good for the planet.

Retailers and manufacturers are getting to grips with the Returns cycle – now they have to contemplate Repairs as well. But with ‘right-size’ auto-boxing technology, at least the pack and despatch side is more manageable.

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Smoothing the Curve for Peak Ecommerce Performance

Posted on by David Priestman

Ecommerce fulfilment is prone to frequent and often dramatic spikes in demand, and this causes retailers significant challenges in the packing area. How can businesses smooth the curve and cope with these peaks when labour resources are so scarce? Jo Bradley (pictured below), Business Development Manager, Sparck Technologies, comments.

Peak periods stress-test the whole fulfilment and delivery process and nowhere is this more acutely felt than in the packing area. Constructing boxes, packing, weighing, sealing and labelling manually is a slow process, and few shippers have either the space or the available labour to create additional packing stations for what may be only a few days’ work. And as everyone knows finding flexible labour, available at short notice, is a major headache. So, how can online retailers respond to these spikes in demand?

The case for greater use of automation in the packing area is compelling. However, simple size-constrained machines using only one-size of box does not cater for the wide variety of products and order sizes experienced by most online retailers. The results are often very wasteful.

Waste not…

It is understood that 60% of ecommerce deliveries are by volume at least a quarter composed of void-fill or just fresh air. The consequences are poor, with higher material wastage, greater chances of product damage and a negative impact on brand image – resulting in higher levels of returns.

Jo Bradley

What can be done?

High-speed fit-to-size ‘auto-boxing’ systems, developed by Sparck Technologies and used by major brands globally, are capable of tailor-making over 1,100 ecommerce packages per hour.
The system scans and measures the item or group of items to be packed and calculates the ‘best fit’ box shape and size. Material for the box and lid is cut and creased to size, erected around the item(s) and the lid glue-sealed – which is faster and more recyclable than using tape. Parcels are weighed, labelled and away.

This approach addresses the waste problem – cardboard usage typically cut by 30%, and a tight fit eliminates the need for void fill. Total package volumes can be reduced by 50%, maximising the use of the truck or trailer cube and reducing shipping costs and environmental impacts.

More cogently for the hard-pressed fulfilment centre manager, at packing rates in excess of 1,100 per hour the latest CVP Everest machine can potentially replace up to 20 manual packing stations. And for businesses with mid-market volumes a similar machine, the CVP Impack, produces up to 500 boxes per hour and offers just about all the benefits of the CVP Everest.

The business case is impressive. Even operating ‘off-peak’ at well below capacity there is a rapid ROI in the form of material savings, lower shipping costs and labour economies – labour that could be redeployed to other tasks, such as picking. But it is at peak times that the CVP Everest and CVP Impack systems really come into their own, ramping up throughput without any corresponding increase in labour, and minimising the burden on despatch and delivery operations.

By choosing an automated solution to ‘right-size’ ecommerce deliveries, retailers can meet their fulfilment promises, even in the busiest peaks, while respecting the environment, reducing transit damage, and saving money.

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Sparck Celebrates 100 years of Innovation

Posted on by David Priestman

This year on June 20th Sparck Technologies, the automated ‘right-size’ boxing specialist, celebrates a century of world-class engineering and innovation. The business has come a long way in a hundred years, from its origins developing the mechanised production of wooden shoes, to a global leader in the design and fabrication of advanced, fit-to-size automated packaging systems for ecommerce applications.

Sparck Technologies’ power to innovate has been a constant throughout its surprising history. Established in The Netherlands as HaDeWe in 1924, the small engineering business displayed its ingenuity early on by moving from repairing windmills to developing and building machines that would revolutionise the production of wooden clogs. And by the 1950’s it had reinvented itself again, boosting the productivity of office workers around the world with its cutting-edge mailroom solutions capable of folding and filling thousands of envelopes per hour.

Its success in developing novel concepts – rethinking mailroom products for desk-top use – went global, setting the pace for future innovation. As part of Quadient for over 30 years, the business continued to tap into its creative DNA, and deep engineering know-how, to push the limits of what’s possible in mailroom and despatch operations, culminating in 2013 with the multiple award-winning development of ‘right-size’ auto-boxing technology. Ecommerce fulfilment would never be the same again.

Using advanced 3D scanning technology to optimally size, create and label each box in one seamless process, Sparck’s CVP Impack can produce 500 boxes per hour, typically replacing up to 20 packing desks, and enabling businesses to grow and flex at peak, even when labour resources are tight. Package volumes are reduced by up to 50%, cutting cardboard usage by 30% and eliminating the need for void fill.

The machine heralded a revolution in ecommerce packaging, with a torrent of international sales that has seen Sparck’s CVP systems supplied, installed and supported in over 15 countries across the globe.

Technological advances have continued apace and in 2019 the CVP-Everest was launched to world-wide acclaim. The machine offered businesses throughput rates of up to 1,100 boxes per hour, with dual input stations and up to three cardboard stock feeds.

Now as an independent company for the last three years, Sparck Technologies continues to innovate, leading the field with advances that deliver huge competitive advantage, including: a high-speed print-on-box facility, the capability to produce ultra-low profile boxes of just 28mm – enabling businesses to benefit from boxes that are letter rate compliant in the USA and most European countries – and most recently auto-induction, which removes the need for an operator, allowing a seamless transit of orders from picking station to packing and despatch.

One hundred years on Sparck Technologies continues to push the boundaries of what’s possible in automated postal-related packaging. To date over 220 million ‘right-size’ boxes have been produced on Sparck’s revolutionary fit-to-size packaging machines worldwide.

Today, Sparck Technologies is based in Drachten, a site it has occupied since 1947. From here the business serves a fast-growing international market for highly automated, sustainable packaging solutions suited to the ecommerce sector – packaging automation that can, almost instantaneously, tailor make individual compact, right-size boxes for over 1,100 ecommerce orders an hour. No wastage of materials, no shipped air and only minimal dependency on labour.

What will the next 100 years bring?

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Manufacturers Face Complexity of Spare Parts Boom

Posted on by David Priestman

The kickback against the ‘throw-away’ consumer society is gathering pace, with manufacturers under increasing pressure to stock and supply spare parts. However, the consequences for manufacturers’ fulfilment and packing lines are significant. Jo Bradley, Business Development Manager at Sparck Technologies, explains why.

The ‘Right to Repair’ movement has already seen legislation passed in four US States – California, New York, Colorado, and Minnesota. While, the UK now requires manufacturers of consumer durables such as washing machines, fridges and televisions to supply consumers with spare parts for ‘simple and safe’ repairs, and make parts for trickier jobs available to professional repairers. Support will have to remain available for between seven and ten years.

This brings the UK in line with existing EU rules. But the UK is about to go further. In March 2023 The Commission adopted a proposal on common rules promoting the repair of goods, which are now being discussed. However, importantly, this is with a view to extending coverage beyond consumer durables to other goods, including smartphones and a much wider band of consumer electronics, that may otherwise end up in the WEEE (Waste Electrical and Electronic) waste stream.

Interestingly, some of the American States have started at the other end of the spectrum, on automotive and agricultural equipment, with consumer goods to come later. But it’s almost certain that consumer expectations around repairability across sectors will converge, probably leaving legislation to catch up.

Spare parts fulfilment challenge

For OEMs and their agents, this trend poses many challenges, from product design onwards. One of these is that many will have to establish a comprehensive and complex spare parts operation, in some cases for the first time. Instead of occasionally supplying small numbers of parts, from current products, to official dealers to meet warranty claims, OEMs will need to supply even obsolescent items, not just to dealers, but to third party repairers, the growing number of ‘community’ repair/reuse organisations and, where safety considerations allow, to individual consumers.

And whereas most consumer goods are shipped to the point of sale in their own boxes, perhaps with some foam protectors for the corners, spare parts will require a completely different approach to fulfilment and packaging. Unpredictable combinations of often small, possibly fragile, parts will have to be safely and securely boxed for shipment. Suddenly, OEMs need far more sophisticated packing lines.

Labour costs

Traditional, labour-intensive packing operations are expensive. Businesses that already supply an aftermarket often make reasonable margins on spares, where items can regularly be pulled from production and packaged in occasional periods of relative inactivity. A full-blown, high volume spares operation, likely picking and packing from its own store and inventory, is a different story entirely and may well be a significant commitment in both working capital and labour. Apart from labour costs, think of all the multitude different box sizes that will need to be kept in stock and the consequences of not having the right sized box available to packers.

Automation can be deployed to reduce labour costs in the packing operation. However, merely automating the piling of parts into any available box with some void-fill won’t do. Not only are small components liable to get lost amongst the crumpled paper or styrene beads, or damaged as they shake about, but the profile of consumer most likely to demand repairability and sustainability is the least likely to be impressed by spares arriving in oversized boxes, with all the waste of carboard and other materials this implies.

‘Right-sizing’ boxes

Luckily for businesses serving the parts market, advanced packaging technology is now available that can ‘right-size’ boxes for single or multiple item orders. These machines automatically scan an order and produce the optimum sized box at great speed – going a long way to controlling costs.

Sparck Technologies’ CVP Impack and CVP Everest machines do exactly that. These machines calculate the optimum shape and size of box required, which is then automatically cut, creased, erected, sealed, weighed and labelled. With the capacity to generate over 40 million unique box sizes, this equips companies with the agility and flexibility as they navigate future legislation and demand. The highest-volume machines can make up to 1,100 boxes per hour – an equivalent throughput on manual packing lines may take up to 20 staff. Usefully for this sector, ultra-low profile boxes of just 28mm can be created.

Right-sizing typically saves 30% or more in cardboard, besides eliminating void-fill, so meeting consumer expectations on sustainability. Right sizing also generates significant economies in transport and post/courier charges. The demand for repairability will only grow. Businesses can prepare for these changes and capitalise on the opportunities, not just to reduce costs but to secure competitive and reputational advantage.

Little Green Bag Enhances Sustainable Operations

Posted on by Keith McKinley

The Little Green Bag, a leading Dutch fashion retailer known for its carefully curated selection of niche clothing and accessories, announces a strategic partnership with CMC, a pioneer in innovative packaging solutions. This collaboration marks a significant step towards enhancing operational efficiency while upholding their commitment to environmental sustainability.

Founded in 2008 by Aramis and Maria Gandjapour a dedicated Dutch couple in Vlaardingen, The Little Green Bag has grown from a small bag retailer to a thriving online platform offering a diverse range of products to include jewellry and accessories, now serving a global clientele. From the beginning, the company has focused in providing a personalized experience and delivering quality products that are both stylish and sustainable. Acknowledging the necessity to adapt to the increasing demands of their growing customer base, the company sought innovative solutions to streamline their operations.

The turning point came when The Little Green Bag decided to venture into online retail, using the house as a warehouse. The growth was phenomenal and this surge in demand necessitated a larger warehouse; in 2012, they invested in a 100 m2 facility. Now, they operate in a vast space of 9,000 m2 with a workforce of 150 people, serving customers globally through a multilingual website.

Sustainable Operations

The rapid surge in orders, particularly during peak periods when order volumes reach up to 8,000 per day presented a packaging challenge for The Little Green Bag. The need to handle a substantial volume of single-line orders while minimizing packaging waste was imperative. Enter CMC and their revolutionary packaging solution, CMC Paper-Pro.

CMC Paper-Pro, a fully automated paper bagging system, was a game-changer and proved to be the perfect fit for The Little Green Bag’s evolving needs. By transitioning from traditional boxes to paper-wrapped bags, the company significantly reduced material consumption and shipping volumes, enhancing operational efficiency and reducing their environmental impact. The system’s flexibility allowed for customization, optimizing warehouse space in a high-cost area.

Lawrence van de Meeberg, Director of e-commerce at The Little Green Bag expressed enthusiasm about the collaboration, stating, ” CMC’s approach was impressive. They understood our specific needs and supported us in customizing the footprint to minimize waste and make our operations more sustainable. The integration of CMC Paper Pro has allowed us to not only enhance operational efficiency but also make significant strides in reducing our environmental footprint. It aligns perfectly with our vision of offering quality products sustainably and efficiently.”

Ed Savelsbergh, General Manager of CMC Packaging Automation NL, says “The Little Green Bag continues to thrive as a small department store, offering luxury within reach for all, while maintaining meticulous curation and personal involvement in the product selection process. We are proud to support their business with our technology to enhance efficiency and guarantee a great customer experience.”

Both companies are optimistic about the positive impact this partnership will have on the future of The Little Green Bag. By combining their expertise and innovative solutions, they aim to further elevate their offerings and ensure a seamless shopping experience for their global clientele.

e-commerce Box-making Solution

Posted on by David Priestman

Emmeci, a Coesia company in the design and manufacturing of machines and systems for the production of premium packaging, launches E-BM, a complete fit-to-size box making solution for the e-commerce sector.

The ideal packaging is fit-to-size, compact and robust

With e-commerce, the packaging must follow the object’s dimension, to ensure its integrity first and foremost. E-BM produces extremely robust packs: the base of the pack comprises a single piece with no bottom closure, and the corners are reinforced with a double layer of material. The result is an improved resistance to protect items during delivery and a better customer experience. The E-BM is engineered to integrate seamlessly with warehouse control and management systems, enabling the dimension of the packaging to be adapted automatically to end product, on-demand.

The ability to produce right-size packaging means up to 40% smaller packaging sizes (compared to the standard shipping boxes commonly used on the market) and less raw material, saving on paper. Fit-to-size boxes are also more manageable in the downstream phase of the supply chain, facilitating handling and space as well as transport optimization during shipping or delivery, resulting in reduced emissions and inventory footprint.

Up for the challenge

Logistics hubs primarily need systems capable of handling, sorting and packing an increasing number of products of different shapes and sizes. That is why using a partner combining long-term experience in developing rigid box packaging solutions like Emmeci with the strength of a leading industrial automation group like Coesia is crucial. Emmeci and Coesia have created E-BM; a packaging machine specifically designed for the e-commerce sector. E-BM packs into boxes a wide range of goods from sectors such as electronics or fashion, including tablets, PCs, clothing and many other everyday items.

Flexibility and customization

E-BM flexibility allows not just to automatically adapt the box to the dimensions of the product to be shipped, but also to customize the packaging in many different ways, including tape closure. It also offers numerous options for printing codes and labels to assist in package control and traceability processes.

The benefits of having a single partner

Choosing Coesia as a single partner in the e-commerce industry offers infinite advantages, first and foremost that of having an end-to-end solution provider. Coesia seamlessly guides its clients through every leg of their e-commerce automation journey, spanning from box making and filling, through inline printing, up to palletizing. Coesia’s e-commerce solutions revolve around three key domains, finely tuned technologies to elevate operations and ensure customer satisfaction.

Firstly, Coesia pack automation solutions redefine wrapping, box making, box filling and inline printing for the e-commerce industry. Tailored to perfection, these solutions cater to the need for right-sized, customized package, ensuring a superior customer experience.

Secondly, the E-Fulfilment solutions usher in a new era of process automation, meticulously crafted to address the ever-evolving challenges faced by e-commerce players. From conveying solutions to ground-breaking sorting equipment, the portfolio is designed to optimize every facet of their operations.

Lastly, Coesia advanced robotics capabilities ensure secure handling of a diverse array of products, boxes, and cases, for a seamless journey from picking systems to palletizing and depalletizing equipment.

In the dynamic world of e-commerce, Coesia shines as a pioneer in cutting-edge technology and customer-focused solutions. Innovation and user-friendliness are at the core of highly advanced technological solutions, all geared towards delivering agility, flexibility, and efficiency.

A sector experiencing double-digit growth

The e-commerce packaging sector is worth around 60 billion dollars globally and is more dynamic than ever. According to forecasts, it will grow by 13.8% over the next five years to over USD 115 billion in 2028. E-commerce is now the preferred sales channel for a wide range of goods, including consumer goods, food, hi-tech and fashion. The sector’s expansion involves more than logistics and transport; the related packaging world is also experiencing growth and change.

CMC’s new Chief Digital and Operations Officer

Posted on by Keith McKinley

CMC Packaging Automation is pleased to announce the appointment of Domenico Gallozzi as the new Chief Digital and Operations Officer. With over two decades of executive management experience in the operations of various global industries, Domenico brings a wealth of expertise in efficiency creation, process optimization, and reengineering to his new role.

Domenico Gallozzi has held leadership positions in esteemed organizations including Coesia, Philips-Saeco, Stevanato Group, and Indesit Company. As a Mechanical Engineer with an impressive track record, he has excelled in managing both B2C and B2B markets at local and international levels, showcasing his strong understanding of factory management, operation strategy, project management, lean six sigma implementation, and new product startups.

In his new role at CMC Packaging Automation, Domenico has been entrusted with the vital task of spearheading the company’s digital transformation initiatives. He will also oversee Global Operations, Customer Service, Health and Safety, further bolstering the company’s commitment to operational excellence.”

“Domenico’s extensive experience and dynamic leadership style make him an ideal fit for the role of Chief Digital and Operations Officer at CMC Packaging Automation. His in-depth knowledge of various operational facets and strategic acumen will play a pivotal role in steering our company towards continued growth and success,” said Francesco Ponti, CE0 at CMC Packaging Automation.
Domenico Gallozzi expressed his enthusiasm for his new role, stating, “I am honored to join the CMC Packaging Automation team and further contribute to its journey of transformation and innovation. I look forward to leveraging my experience and passion for driving efficiency to enhance operations and position CMC Packaging Automation as an industry leader.”

With this appointment, CMC Packaging Automation reinforces its commitment to staying at the forefront of digital innovation and operational excellence in the packaging automation industry.

Based in Città di Castello (PG), CMC Spa is a company in the portfolio of KKR Global Impact Fund and supported by Amazon’s Climate Pledge Fund engaged in the design, production, and sale of innovative solutions and high-tech machinery for mailing, graphic art, e-commerce, and logistics. Founded in 1980, the company has dedicated itself to developing strategies that could transform it into the leading provider of technologies, services, components, and professional technical training. CMC has always been attentive to promptly respond to the changing market demands with creative projects and tailor-made solutions. With the exponential growth of e-commerce reshaping the shipping industry, CMC now assists retailers and logistics companies in optimizing the order fulfilment process and using sustainable, robust, highly personalized, and secure packaging through its popular and award-winning 3D packaging technology, which perfectly adapts to the content of the package.

Right Size Packaging Automation

Posted on by David Priestman

A leading US automotive parts business has reduced manual packing constraints by adopting right-size packaging automation, helping the business meet increasing order volumes and supporting current customer demands and future growth.

ECS Tuning has a long and celebrated history supporting the European car community in the USA. From its beginnings as a family-operated service shop in 1962, ECS has become the leading distributor of genuine, after-market, and performance parts for Audi, BMW, Mercedes Benz, MINI, Porsche, and Volkswagen.

Parts Packaging Automation

In 2006, ECS decided to no longer accept or schedule service appointments, but concentrate its energies on increasing part and accessories sales, with ongoing improvements to customer service. A fast-growing inventory forced ECS to relocate to a new facility in 2009, trebling their space to accommodate their rapidly expanding business. Since, their staff has grown fivefold and the extra floor space is long gone, filled with parts, products, and equipment.

In that scenario, with over 1.3 million part numbers in their catalogue and all operations handled in house, ECS recognised that they did not have enough capacity in their manual packing process to consistently meet customer needs or expectations.

Fast fit-to-size packaging

ECS turned to Sparck Technologies’ CVP Impack Automated Packaging Solution to support their current demands and future growth. With this inline auto-boxing technology, each unique single- and multi-item order is 3D scanned on demand to determine the minimum box size required. Then, corrugated cardboard is custom cut to eliminate unnecessary volume and reduce or eliminate the need for void fill materials. Finally, the order is auto-boxed in a fit-to-size parcel, taped, weighed, and labelled for shipping.

By creating a right-sized box every 7 seconds, ECS can count on higher throughput and better use of labour resources. The CVP Impack can perform the work of roughly 20 human packers in an eight-hour period. This allows ECS to remove the manual packing choke points while improving the efficiency of their existing staff for higher-value tasks.

Better customer experience

From the customer-facing side, the CVP Impack will auto-box up to 70% of their catalogue with little to no void filler or packing material. This allows ECS to improve their customer experience with sustainable packaging that is easy to recycle or reuse.

“With more associates picking orders, and a machine that can handle the volume, we anticipate a substantial increase in the number of orders moved out the door daily. That efficiency improvement translates to promises kept on shipping times with in-stock orders that are ready to ship on the same day,” says Max Everhard, GM of Special Operations at ECS Tuning.

Sparck Technologies (previously known as Packaging by Quadient) is a global leader in the design and fabrication of advanced, fit-to-size automated packaging systems for high-volume ecommerce applications – award-winning sustainable packaging solutions that eliminate excessive packaging. Sparck aims to make every parcel its clients send out a brand ambassador for their business. Based in Drachten, The Netherlands, Sparck Technologies supplies some of the world’s largest retail and industrial brands, supporting their ecommerce channels in multiple geographies with market-leading engineering know-how that combines innovation, reliability and unbeatable performance.

www.sparcktechnologies.com

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